Close-die Forming Process And Experimental Study Of Bevel Gear

With the rapid development of auto industry, the quality and precision of bevelgear need to be improved. There’s greatly practical significance to study theclose-die forming of bevel gears and effectively produce bevel gears with highprecision. This paper focusd on some technical problems during the close-dieforming of bevel gear and studied the practical research of such process.With respect to planetary gear, the feasibilty of the close-die forming ofplanetary gear wasstudied. FEA software DEFORM-3D was used to numericallysimulated such process. Filling ability of tooth profile was analyzed. Distributioncharacristics of strain field and velocity field was obtained as well as cuve of load.The effects of billets size, fictional factor and extrusion velocity on load of formingwere discussed. Simplified die was designed for experiments on lead samples. Theresults show that ordinary press cannot satisfy the need of the close-die forming ofbevel gear.With respect to planetary gear, the close-die forming of bevel gear based onhydraulic formwork was studied further. Forming effect and load case wereanalyzed. Applying the orthogonal experiment design, the punching wad structurewas optimized in order to reduce forming force and a group of feasible structureparameters of punching wad were obtained for instructing the production.Byintroducing the divided flow cavity, the forming load was decreased further.Theexperiments confirm the feasibility of thisis process.Respect to axle shaft gear with large diameter, filling ability and load case ofone-path close-die forming were analyzed. According to the idea of local loading,the scheme of two-path bliterated forging wre designed and improved. Because oflarge forming load, warm and cold composite formation was proposed one-path andtwo-path warm forming were analyzed respectively. Two kinds of sizing value weredesigned for cold sizing and were compared on the filling effects, straindistribution of billets, load of sizing and stress distribution of die during sizing.The resluts show tooth shape formed uniformly with high die life and low load ofdie when sizing value stay in tooth profile.